Flexible Collar for Turbocharger Air Intake Flow Transition
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Solution Overview
Problem
Existing air intake systems face challenges in efficiently transferring air from large internal diameter conduits to smaller external diameter intake flanges, leading to flow interruptions, pressure differentials, and increased manufacturing costs due to the need for frequent retooling for different applications.
Innovation Solution
A flexible collar with a graduated surface, made from materials like polyurethane or silicone, provides an interference fit with the intake flange and conduit, ensuring a smooth air flow and reducing the need for multiple clamps, allowing for a constant internal conduit diameter and customizable sizing to accommodate various flange dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the intake conduit diameter is reduced to match the turbocharger intake flange, then the intake can mate with the turbocharger, but air flow is reduced and pressure losses increase
Solution Approach 1:
The collar introduces a transitional dimensional zone between the large-diameter conduit and small-diameter flange. By creating an intermediate dimension with gradual diameter change rather than abrupt reduction, the collar maintains larger flow cross-section longer while still achieving compatibility with the turbocharger flange.
Solution Approach 2:
The collar employs curved, tapered surfaces to transition air flow from the conduit to the flange. The gradual curvature of the collar's internal passage eliminates sharp corners and abrupt diameter changes, allowing smooth air flow progression and reducing turbulence and pressure losses.
2Ease of operation
If a coupler is used to bridge the intake flange with the intake conduit, then connection is achieved, but air flow is impeded by ridges and additional clamps are required
Solution Approach 1:
The collar is constructed as a flexible, thin-walled component that can be deformed during installation to achieve an interference fit with the flange. This flexibility allows the collar to conform to the flange surface and create a tight seal without requiring rigid fastening elements that would create flow obstructions.
Solution Approach 2:
The collar design extracts and eliminates the need for separate coupler components, multiple clamps, and sealing elements. By integrating the sealing, connecting, and flow-guiding functions into a single collar component, the design removes the harmful ridges and additional hardware that would impede air flow.
3Ease of manufacture
If the intake conduit is manufactured with a fixed configuration, then manufacturing costs are reduced, but the intake cannot accommodate different flange dimensions
Solution Approach 1:
The collar serves multiple functions: it acts as a connector between conduit and flange, provides sealing through interference fit, guides air flow with its tapered surface, and adapts to different flange sizes. This multi-functionality allows a single collar design to replace multiple specialized components, achieving versatility without increasing manufacturing complexity.
Solution Approach 2:
The collar's dimensional parameters (internal diameter, external diameter, length, taper angle) can be adjusted to match different flange specifications. By varying these parameters while maintaining the same basic collar geometry and material, manufacturers can produce compatible intakes for different applications using similar manufacturing processes and tooling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances air flow efficiency, reduces pressure differentials, and minimizes manufacturing costs by enabling a single air intake system to fit multiple applications, with improved throttle response and reduced lag in turbocharged engines.
Implementation Method 1
The collar may be formed from a rubber-like material such as polyurethane, silicone, or other suitable materials designed to comply with, and effectively seal the engine's intake tract
Implementation Method 2
a graduated side surface for directing air flow
Data Source
AI summary
An intake flow device and system for coupling a turbocharger's compressor intake to an air intake is disclosed. The flow device may be cylindrically shaped, flexible, and configured to fit on an intake flange of the compressor. An intake conduit may be fitted around the flow device, such that the intake conduit may retain a large diameter for increased air flow, rather than necking down to mate with the intake flange. The flow device may incorporate compression ribs around its outer circumference for positively mating with the air intake conduit and may incorporate a recess within its interior for securely mating to a lip on the intake flange. The flow device may also be graduated to direct air from the intake conduit to a smaller diameter compressor intake. Guide vanes may also be provided within the flow device to control and direct air to the inlet of the turbocharger.